Packaging inserts

ABSTRACT

A packaging insert comprising a combination of corrugated cardboard and honeycomb paperboard, and packaging assemblies and methods of packaging an item utilizing one or more such packaging insert(s), as shown and described.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/961,282 filed Jan. 15, 2020, the entirety of which is hereby incorporated herein by reference for all purposes.

TECHNICAL FIELD

The present invention relates generally to the field of packaging, and more particularly to packaging inserts constructed of a combination of corrugated cardboard and honeycomb paperboard, such as for example top cap and base pad packaging inserts for water heater packaging.

BACKGROUND

Traditionally, water heaters are packaged in cardboard boxes with closed-cell extruded polystyrene foam (XPS or Styrofoam™) endcaps for protection against impacts and drops. FIG. 1 shows a typical foam cap packaging arrangement.

Continued improvements to packaging technologies are sought. It is to the provision of improved packaging such as packaging inserts for water heaters, that the present invention is primarily directed.

SUMMARY

In example embodiments, the present invention provides improved packaging inserts constructed of a combination of corrugated cardboard and honeycomb paperboard. In example applications, the packaging inserts are configured as top cap and base pad packaging inserts for water heater packaging. Packaging according to example embodiments of the invention may provide improved performance, reduced costs, facilitate recycling, and avoid potential negative environmental effects and health concerns that may be related to polystyrene foam.

In one aspect, the present invention relates to a packaging insert comprising a combination of corrugated cardboard and honeycomb paperboard. In particular examples, the packaging insert includes a corrugated cardboard material attached to a honeycomb paperboard material. The packaging insert preferably has a surround portion and a cover portion, and the surround portion and the cover portion are attached to one another by a foldable section of material.

In another aspect, the invention relates to a packaging assembly comprising an outer box or carton, and at least one packaging insert comprising a combination of corrugated cardboard and honeycomb paperboard configured for placement in the outer box or carton around a packaged item.

In another aspect, the invention relates to a packaging system for packaging a packaged item. The packaging system preferably includes a base packaging insert with a corrugated cardboard material attached to a honeycomb paperboard material. The base packaging insert preferably further includes a base surround portion and a base cover portion. The base surround portion preferably defines a base cutout section configured to receive a base portion of the packaged item. The packaging system preferably also includes at least one top packaging insert with a corrugated cardboard material attached to a honeycomb paperboard material. The top packaging insert preferably further includes a top surround portion and a top cover portion. The top surround portion preferably defines a top cutout section configured to receive a top portion of the packaged item.

In still another aspect, the invention relates to a method of packaging a packaged item, the method comprising placement of at least one packaging insert comprising a combination of corrugated cardboard and honeycomb paperboard within an outer box or carton around the packaged item.

In another aspect, the invention relates to a method of packaging a packaged item. The method preferably includes placement of at least one packaging insert formed of a combination of corrugated cardboard and honeycomb paperboard within an outer box around the packaged item. The at least one packaging insert preferably further comprises a surround portion and a cover portion. The surround portion preferably defines a cutout section forming at least one wall configured for engagement with the packaged item.

These and other aspects, features and advantages of the invention will be understood with reference to the drawing figures and detailed description herein, and will be realized by means of the various elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following brief description of the drawings and detailed description of example embodiments are explanatory of example embodiments of the invention, and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows traditional polystyrene foam packaging inserts used in packaging of a water heater.

FIG. 2 shows improved packaging inserts constructed of a combination of corrugated cardboard and honeycomb paperboard, utilized in water heater packaging according to an example embodiment of the present invention.

FIG. 3 shows a preform assembly for producing a corrugated cardboard and honeycomb paperboard assembly according to an example embodiment of the present invention.

FIG. 4 shows the corrugated cardboard and honeycomb paperboard preform assembly of FIG. 3 separated into a pair of top cap packaging inserts, according to an example embodiment of the present invention.

FIGS. 5 and 6 show additional details of the top cap packaging inserts of FIG. 4.

FIGS. 7A and 7B show additional details of example materials of construction for forming the corrugated cardboard and honeycomb paperboard preform assembly of FIG. 3 and the packaging inserts of FIGS. 4-6, according to an example embodiment of the present invention.

FIGS. 8A, 8B, 8C and 8D show additional details of example materials of construction and steps of the fabrication process of the corrugated cardboard and honeycomb paperboard preform assembly of FIG. 3 and the packaging inserts of FIGS. 4-6, according to an example embodiment of the present invention.

FIGS. 9 and 10 show a corrugated cardboard and honeycomb paperboard base pad packaging insert according to an example embodiment of the present invention.

FIGS. 11A and 11B show additional details of example materials of construction for forming the corrugated cardboard and honeycomb paperboard base pad packaging insert of FIGS. 9 and 10, according to an example embodiment of the present invention.

FIGS. 12A, 12B, 12C and 12D show additional details of example materials of construction and steps of a fabrication process for forming the corrugated cardboard and honeycomb paperboard base pad packaging insert of FIGS. 9 and 10, according to an example embodiment of the present invention.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

The present invention may be understood more readily by reference to the following detailed description of example embodiments taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this invention is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed invention. Any and all patents and other publications identified in this specification are incorporated by reference as though fully set forth herein.

Also, as used in the specification including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment.

With reference now to the drawing figures, wherein like reference numbers represent corresponding parts throughout the several views, FIG. 1 shows traditional polystyrene foam packaging inserts P used in packaging of a water heater. FIG. 2 shows first and second improved top cap packaging inserts 10, 110 utilized in a packaging box B for a water heater WH according to an example embodiment of the present invention. FIGS. 3-8 show additional details of the construction and use of the top cap packaging inserts 10, 110. While shown in connection with example embodiments of packaging for a water heater WH, the invention also includes packaging inserts, systems and methods of packaging for use in connection with other types of packaged items as well. The particular dimensions and configurations depicted in the drawings are by way of example only and may vary in different embodiments to accommodate different shapes and sizes of the outer packaging box B and/or of the water heater WH or other packaged item(s). In example embodiments, the water heater WH has a generally cylindrical exterior sidewall configuration, and generally planar (circular) top and bottom end walls.

The first and second top cap packaging inserts 10, 110 are constructed of a combination of corrugated cardboard 20 and honeycomb paperboard 40. In an example method of manufacturing, the first and second top cap packaging inserts 10, 110 are constructed together as a preform assembly 60, as shown in FIG. 3. The assembly 60 is partially or nicked-thru-cut by die-cutting along a score or break line 62 as shown in FIGS. 8A-8D (collectively referred to as FIG. 8). Fold lines 64, 66 may also be formed as indicated by slit-scoring. The assembly 60 can be delivered to the packaging line intact, and separated along the score line 62 and folded along fold lines 64, 66 to form the top cap packaging inserts 10, 110 at the time of use in packaging a 50-gallon or other size of water heater WH or other item(s). Alternatively, the separation and assembly of the top cap packaging inserts 10, 110 can be completed during fabrication and delivered as separate parts. Optionally, multiple assemblies 60 can be formed together (see FIG. 8) and separated by cutting along cut lines 68, 70.

In the depicted example embodiment, the preform assembly 60 comprises a generally rectangular assembly of at least one layer (and optionally two or more layers) of hexacomb core honeycomb paperboard material laminated or glued to at least one layer (and optionally two or more layers) of a corrugated flute cardboard material. In the depicted example embodiment, the preform assembly 60 comprises a first semicircular or arcuate cutout region 12 along one side, and a second semicircular or arcuate cutout region 112 along the opposite second side. In example embodiments, the semicircular cutout regions 12, 112 span an arc of about 60°-120°, for example about 90°; or about ⅙ to about ⅓, for example about ¼ of a full circle; and are generally centered along the sides of the assembly between linear end segments adjacent corners of the assembly. A cut line (nicked thru-cut) extends transversely across the width of a medial portion of the preform assembly 60 allowing the preform assembly to be separated into two separate packaging inserts. The first fold line 64 is positioned between the cut line and the second semicircular cutout region 112. The second fold line 66 is positioned between the cut line and the first semicircular cutout region 12, for example immediately adjacent a rectangular cutout portion extending from the first semicircular cutout region.

In example embodiments, and as seen best in FIGS. 5, 6 and 8, the top cap packaging inserts 10, 110 comprise two layers (40A, 40B) of 1.75″ thick hexacomb core type 4 honeycomb paperboard 40 with a panel of double-wall corrugated 350 B/C flute cardboard 20 laminated or glued to the top of the honeycomb material. The semi-circular cutout regions 12, 112 are formed in each of the top cap packaging inserts 10, 110 by thru-cutting and removal of sections of the first layer 40A from the second layer 40B for engagement around the circumferential side edge of the top of the water heater WH. When formed and folded as shown, the top cap packaging inserts 10, 110 comprise a surround portion or layer S and a cover portion or layer C. The surround portion or layer S includes the semi-circular cutout regions 12, 112, and is configured to engage sides of the water heater or other packaged item to prevent lateral side-to-side shifting of the packaged item within the outer box or package and protect against side impacts. The cover portion or layer C is configured to overlie at least a portion of an end (top or bottom) of the packaged item to prevent axial up-and-down shifting of the packaged item within the outer box or package and protect against end impacts. Each of the surround portion and the cover portion preferably includes at least one layer (and optionally two or more layers) of hexacomb core honeycomb paperboard material laminated or glued to at least one layer (and optionally two or more layers) of a corrugated flute cardboard material. In example embodiments, the surround portion and the cover portion are foldably connected to one another by a perforated and/or partially scored section of material at the fold lines, with the underlying hexacomb core honeycomb paperboard layer(s) cut through or partially removed to allow folding of the cardboard layer(s). The surround portion of packaging insert 10 (FIG. 5) includes first and second side portions with an open segment therebetween formed by a rectangular outward extension of the semi-circular cutout region 12, with the first and second side portions defining curved surround wall portions between the outer face of cardboard layer 20 and the interior face of the cover portion. The surround portion of packaging insert 110 (FIG. 6) includes a single curved surround wall portion extending across the width of the insert between the outer face of cardboard layer 20 and the interior face of the cover portion. In the depicted embodiments, the cover portion comprises a substantially continuous generally rectangular body.

FIGS. 7A and 7B (collectively FIG. 7) and FIGS. 8A, 8B, 8C and 8D (collectively FIG. 8) show a fabrication or assembly process according to example forms of the invention. One or more layers (for example two layers 40A, 40B) of honeycomb paperboard 40 (for example, 1.75″ thick hexacomb core type 4 honeycomb paperboard 40) is/are laminated or glued to a panel of corrugated cardboard 20 (for example, a double-wall corrugated 350 B/C flute cardboard 20) to form an assembly panel. The assembly panel and/or the constituent layers thereof is/are cut and scored to form one or more preform assemblies or blanks 60 (for example FIG. 8A shows a panel forming an array of four preform assemblies 60). The preform assemblies are separated and folded as shown in FIG. 8C, to form the top cap packaging inserts 10, 110 as shown in FIG. 8D.

FIGS. 9-12 show a corrugated cardboard and honeycomb paperboard base pad packaging insert 210 according to another example embodiment of the present invention. Similar to the above described embodiment, a layer of double-wall corrugated cardboard 220 is glued or laminated to two layers of honeycomb paperboard 240, and scored with cut line 262 and fold lines 264. A circular cutout 212 is formed by thru-cutting and removal of sections of the first layer of honeycomb material from the second layer for engagement around the circumference of the bottom of the water heater WH. One or more cutout extension regions 214 may also be formed to accommodate outwardly projecting parts of the water heater in packaging. One or more preform assemblies can be formed together (for example, FIG. 12A shows an assembly panel comprising two preform assemblies). The preform assemblies are separated and folded as shown in FIG. 12C, to form the base pad packaging inserts 210 as shown in FIG. 12D.

In the example embodiment shown, the base pad packaging insert 210 comprises a surround portion or layer S and a cover portion or layer C. The surround portion or layer S includes the generally circular cutout region 212, and one or more arcuate wall portions or segments configured to engage sides of the water heater or other packaged item to prevent lateral side-to-side shifting of the packaged item within the outer box or package and protect against side impacts. The cover portion or layer C comprises a substantially continuous generally rectangular body configured to overlie at least a portion of an end (top or bottom) of the packaged item to prevent axial up-and-down shifting of the packaged item within the outer box or package and protect against end impacts. Each of the surround portion and the cover portion preferably includes at least one layer (and optionally two or more layers) of hexacomb core honeycomb paperboard material laminated or glued to at least one layer (and optionally two or more layers) of a corrugated flute cardboard material. In example embodiments, the surround portion and the cover portion are foldably connected to one another by a perforated and/or partially scored section of material at the fold lines, with the underlying hexacomb core honeycomb paperboard layer(s) cut through or partially removed to allow folding of the cardboard layer(s).

In use, a base pad insert 210 is optionally installed at the bottom of a carton or box B for packaging a water heater WH. The water heater is supported in the box on the base pad insert 210. The top cap packaging inserts 10, 110 are then prepared and placed around and over the top of the water heater WH in the box B, and the box is closed and sealed. The arcuate wall(s) of the surround portions or layers of the packaging inserts formed by the circular and/or semi-circular cutout regions closely conform to and engage around the correspondingly shaped sidewall surfaces of the water heater WH or other packaged item, and the cover portions or layers overlie the endwall surfaces of the water heater WH or other packaged item. In example embodiments, the packaging inserts 10, 110, 210 are configured to allow the packaging to pass ISTA water heater packaging drop test, tip-over test, and/or other applicable shipping and packaging tests and standards, without the use of polystyrene foam components. Also, while depicted in use with packaging of a 50-gallon cylindrical water heater, the packaging inserts may be configured for use with other sizes and configurations of water heaters, and/or in the packaging and shipping of various other items not limited to water heaters. In example embodiments, the packaging insert, packaging system, and packaging methods comprise no polystyrene foam, and are formed entirely or substantially entirely of easily recyclable paperboard and cardboard materials of construction.

While the invention has been described with reference to example embodiments, it will be understood by those skilled in the art that a variety of modifications, additions and deletions are within the scope of the invention, as defined by the following claims. 

What is claimed is:
 1. A packaging insert comprising a corrugated cardboard material attached to a honeycomb paperboard material, the packaging insert further comprising a surround portion and a cover portion, and wherein the surround portion and the cover portion are attached to one another by a foldable section of material.
 2. The packaging insert of claim 1, wherein the surround portion comprises a cutout section forming at least one wall portion configured for engagement with a packaged item.
 3. The packaging insert of claim 2, wherein the cutout section of the surround portion is semicircular and forms at least one arcuate wall portion.
 4. The packaging insert of claim 3, wherein the semicircular cutout section forms two arcuate wall portions.
 5. The packaging insert of claim 2, wherein the cutout section of the surround portion is circular and forms at least one arcuate wall portion.
 6. The packaging insert of claim 5, wherein the circular cutout section forms four arcuate wall portions.
 7. The packaging insert of claim 2, wherein the cover portion comprises a substantially continuous generally rectangular body.
 8. The packaging insert of claim 2, wherein the packaged item is a generally cylindrical water heater.
 9. The packaging insert of claim 1, wherein the corrugated cardboard material comprises a double-wall corrugated 350 B/C flute cardboard.
 10. The packaging insert of claim 1, wherein the honeycomb paperboard material comprises a hexacomb core type 4 honeycomb paperboard.
 11. The packaging insert of claim 10, wherein the honeycomb paperboard material is at least about 1.75″ thick.
 12. The packaging insert of claim 1, formed from a preform assembly comprising the corrugated cardboard material and the honeycomb paperboard material, wherein the packaging insert is formed by cutting and folding the preform assembly.
 13. The packaging insert of claim 1 comprising no polystyrene foam.
 14. A packaging assembly comprising the packaging insert of claim 1 in combination with an outer box configured to receive a packaged item, with the packaged item being held in place in the outer box by the packaging insert.
 15. A packaging system for packaging a packaged item, the packaging system comprising: a base packaging insert comprising a corrugated cardboard material attached to a honeycomb paperboard material, the base packaging insert further comprising a base surround portion and a base cover portion, the base surround portion defining a base cutout section configured to receive a base portion of the packaged item; and at least one top packaging insert comprising a corrugated cardboard material attached to a honeycomb paperboard material, the top packaging insert further comprising a top surround portion and a top cover portion, the top surround portion defining a top cutout section configured to receive a top portion of the packaged item.
 16. The packaging system of claim 15 comprising no polystyrene foam.
 17. The packaging system of claim 15, wherein the base surround portion and the base cover portion are attached to one another by a foldable section of material, and wherein the top surround portion and the top cover portion are attached to one another by another foldable section of material.
 18. The packaging system of claim 15, wherein the base cutout section is circular and forms at least one arcuate wall portion.
 19. The packaging system of claim 18, wherein the circular base cutout section forms four arcuate wall portions.
 20. The packaging system of claim 15, wherein the top cutout section is semicircular and forms at least one arcuate wall portion.
 21. The packaging system of claim 20, wherein the semicircular base cutout section forms two arcuate wall portions.
 22. The packaging system of claim 15, wherein the packaged item is a water heater, and the base cutout section is configured to receive a base portion of the water heater and the top cutout section is configured to receive a top portion of the water heater.
 23. The packaging system of claim 15, further comprising an outer box configured to receive the packaged item with the packaged item held in place within the outer box between the base packaging insert and the at least one top packaging insert.
 24. The packaging system of claim 15, wherein the at least one top packaging insert comprises first and second top packaging inserts, the first and second top packaging inserts each having a top surround portion defining a top cutout section, the top cutout sections of the first and second top packaging inserts being configured to receive different top portions of the packaged item.
 25. The packaging system of claim 15, wherein the corrugated cardboard material comprises a double-wall corrugated 350 B/C flute cardboard.
 26. The packaging system of claim 15, wherein the honeycomb paperboard material comprises a hexacomb core type 4 honeycomb paperboard.
 27. The packaging system of claim 26, wherein the honeycomb paperboard material is at least about 1.75″ thick.
 28. A method of packaging a packaged item, the method comprising placement of at least one packaging insert comprising a combination of corrugated cardboard and honeycomb paperboard within an outer box around the packaged item, wherein the at least one packaging insert further comprises a surround portion and a cover portion, the surround portion defining a cutout section forming at least one wall configured for engagement with the packaged item.
 29. The method of claim 28, wherein the packaged item is a water heater. 